New melt filter and automated die lip adjustment at NPE 2024

Nordson Corp.’s Polymer Processing Systems (PPS) division will showcase its latest innovations at the NPE 2024 exhibition May 6-10 at the Orange County Convention Center in Orlando, Fla. (Booths #W8189, W8289). Making their U.S. debut at NPE are the BKG^® HiCon™ K SWE-HD/RS melt filter which helps film and sheet producers use more recycled materials, and the EDI^® Prodigi™ automated lip adjustment system for EDI^® extrusion and fluid coating dies.

“These newest technology innovations are emblematic of our focus on delivering the most efficient, productive, and environmentally sustainable solutions to help OEMs and manufacturers meet today’s most demanding production requirements,” said Andreas Wenzel, Nordson’s PPS division vice president.

Nordson’s PPS division is optimistic about the U.S. economy and is well-positioned for a solid 2024, leveraging its innovation and technology in key market segments. The company foresees a continued focus on sustainability, efficiency, and safety, expecting these factors to continue to shape the future of the plastics industry. This comes against a backdrop of increasing use of automation by companies who seek to expand their business amidst continually changing consumer demands.

In response to these market trends, Nordson is displaying for the first time in the U.S. its two latest products which deliver major benefits in terms of efficiency and greater sustainability for the extrusion industry.

Melt Filter Boosts Sustainability

Nordson will highlight its BKG^® HiCon™ K-SWE-HD/RS filtration system, a unique melt filter that helps film and sheet producers utilize more recycled content. Amidst growing calls for greater sustainability, producers are moving to incorporate more recycled materials. The switch requires innovative technology to facilitate and support the transition to recycled content. Nordson has developed a melt filter, based on its unique backflush technology, that permits the increased use of recycled material while maintaining process stability and end product quality.

Melt filters without a backflushing function have limits when processing recycled material. Contamination levels are high, and the high-cost screens clog fast and require time-consuming changing procedures. By using backflushing, the screens are cleaned from contamination and debris over and over, so producers need fewer filter elements and operators need to perform fewer screen changes.

To cope with the high process pressures especially in blown film applications, the BKG^® HiCon™ K-SWE-HD/RS melt filter is equipped with a patented melt-pressure controlled venting start that fully automizes the filling of the screen cavity after a screen change for maximum pressure consistency. Additionally, the filling is done carefully so that no air entrapments endanger the process or the end product. Producers can rely on a stable process and greater quality of the film.

The new melt filter is designed to handle backflushing and venting clean in a maintenance friendly way. The safety cover can be opened vertically, allowing the operator to reach the filter piston from all sides to facilitate cleaning. 

In a highly successful development project, Nordson worked with RKW, a leading blown film producer in Echte, Germany, who focuses on using recycled content in its film packaging products. The new BKG^® HiCon™ K-SWE-HD/RS was provided to RKW as part of a user test and installed in a three-layer plant.

Lip Adjustment Brings Speed, Safety, and Repeatability

Nordson will also showcase the new EDI^® Prodigi^™ motorized lip actuator system which takes extrusion and coating processes to another level by fully automating the lip gap adjustment – making it faster, safer, and repeatable. This new patent-pending system achieves saving tolerances four times faster than conventional thermal bolt systems, supporting the processor’s need for increased sustainability.

Instead of using non-automated, manually-intensive thermal bolts to control the lip adjustment, the Prodigi^™ die relies on a series of motorized actuators connected to the die’s flexible lip. The installed actuators smoothly translate motor rotation into precise linear movement to locally open and close the lip. The system creates a process that is faster, safer, and more energy efficient because it is completed away from the hot die, at a user interface.

Another benefit of the Prodigi™ system is its high energy efficiency since the motorized actuators operate at a significantly lower temperature than thermal bolts. While the thermal bolts need constant heat during a production run, the motorized lip actuator uses little to no power after achieving steady-state operation, reducing overall energy consumption and environmental impact. Projections show that under normal use the Prodigi™ actuator system would consume less than 1% of the electricity needed annually to operate a comparable thermal die bolt system.

At NPE, Nordson will provide technical presentations on both new technologies:

- Damon Patton, Manager, Business Development-Americas for the BKG® product line, will present on Monday, May 6, at 2 p.m. on the Sustainability stage. His presentation will cover the HD/RS filtration system; additional information can be found at: Improving Blown Film Applications With Melt Filtration - NPE2024: The Plastics Show (mapyourshow.com).

- Sam Iuliano, Chief Technologist for the EDI® product line, will give his talk on Tuesday, May 7, at 4 p.m. on the Innovation stage. His presentation will cover the Prodigi™ system; additional information can be found at New Motorized Extrusion Die Adjustment System Unleashes Dramatic Process Efficiency Improvements, Energy Savings and Enhanced Safety - NPE2024: The Plastics Show (mapyourshow.com).